Method for casting massive structures



H. J. HICK METHOD' FOR CASTING MASSIVE STRUCTURES Dec. 11, 1934.

Filed June '7, 1952 6 Sheets-Sheet l Dec. 11, 1934.

H. J. l-ncK l METHOD FOR CASTING MASSIV STRUCTURES 6 Sheets-Sheet 2 Filed June 7, 1932 gm@ ZJ/5601i y www Dec. yl1, 1934.

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Filed June 7, 1932 H J HICK METHOD FOR CASTING MASSIVE STRUCTURES Dec. 11, 1934. H. J. HlcK METHOD FOR CASTING MASSIVE STRUCTURES Filed June 7, 1932 6 Sheets-Sheet 4 Num.

Dec. 11, 1934. H. J. HIcK METHOD FOR CASTING MASSIVE STRUCTURES Filed June '7, 1932 6 Sheets-Sheet 5 III/1 I Dec. 11', 1934. H, 1. HICK 1,983,757

METHOD FOR CASTING MASSIVE STRUCTURES 4Filed June 7, 1932 6 Sheets-Sheet 6 k h Q Patented Dec. 1l, 1934 UNITED STATES METHOD ron cAs'rING MASSIVE STRUCTURES.

Harry J. Hick, Alliance, Ghio, assigner to The Machined Steel Casting Company, Alliance,

Ohio, a corporation of Ohio i f Application June 7, 1932, serial SNO. 615,841.1.

1 Claim.

My invention relates to methods and apparatus for casting massive structures, such as septic tanks, and the like; which may be precast preferably in permanent molds usually from plastic material such as concrete.

The present invention includes certain improvements set forth but not claimed in my prior application for United States Letters Patent for Methods and apparatus for casting massive structures, filed January 15, 1932, Serial No. 585,721, of which the present application is a continuation 'in part of common subject matter, and the present invention also includes improvements in the methods and apparatus of said prior application.

Generally speaking, casting methods and apparatus available prior to the methods and apparatus of said prior application, whether particularly adapted for casting structures from plastic material such as concrete, or whether adapted for casting structures from molten metallic material, are primarily designed for intermittent and irregular operation, are relatively slow in operation, and thus involve a relatively high cost in machine and man hours per unit of manufactured product.

Methods and apparatus adapted for use in continuous production lines must be capable of relatively rapid operation, and always result in a lower cost in machine and man hours per unit or" manufactured product, than the cost in machine and man hours per unit of the same manufactured product when produced by slower intermittent and irregular methods.

On the other hand, the casting oi massive structures as practiced by the use of the usual methods and apparatus, involves a relatively high cost in machine and man hours per unit or" manufactured product, Without considering reductions in cost attainable by the adoption ci continuous manufacturing methods, due to the fact that casting single units under ordinary conditions is relativelyv slow, because excessive manipulation of the molds or forms is required in preparing the same for pouring and in removing the cast product or structure from the molds.

From another standpoint, in the casting of massive concrete or cement structures as heretofore practiced, particularly when said structures are relatively high or deep dome shells, such as grave vaults, half-sections of septic tanks, or the like, great difficulty has been caperienced in avoiding cracking oi the Wall or wallsei the dome shell during setting of, the

structure after pouring, and heretofore it has always .been considered absolutely necessary to permit the cast dome shell vstructure to reach a. nal set after pouring before removing any or" the'molds, and despite which, losses due to Awall cracking have been relatively high.

Accordingly,y common objects of the invention of said prior application and of the present invention include the provision of improved methods and apparatus for casting massive structures', whereby a substantial reduction is attained vin the machine and man hours required per unit of manufactured product, and by the use oi which continuous manufacturing methods may be carried out for casting massive structured Further common objects of the invention of said prior application and of the present invention include the provision of improved methods and apparatus for casting massive structures, whereby the improved apparatus may be operated or carrying out the improved methods, with rapidity and with a high degree of facility.

Further common objects of the invention of said prior application and of the present invention include the provision of improved methods and apparatus for casting massive structures which are particularly adapted for use in connection with permanent molds, and by the use of which thecast structure may be removed from the molds in a minimum period of time after pouring the structure, and with the requirement of a minimum manipulation of the molds in preparation for pouring and during removal oi the cast structure from the molds.

Further common objects of the invention of said prior. application and of the present invention, include `the provision of improved methods and apparatus for casting massive high or deep dome shell structures, whereby losses due to Wall cracking are reduced to a minimum.

Additional objects of the present invention include the provision of improvements in the methods and apparatus of said prior application, said improvements being particularly directed toward facilitating manipulation of the molds,

both for assembling the molds for casting, and for stripping the molds from the cast product,

like, may be made by the use of similar outer molds, and by interchanging inner molds, and said improvements being further directed towards facilitating the interchanging of the inner molds.

The foregoing and other objects are attained by the methods, apparatus, improvements, combinations, and sub-combinations, which comprise the present invention, and the nature of which is set forth in the following general statement, and preferred embodiments `of which are set forth in the following description, and which are particularly and distinctly pointed out and set forth in the appended claim forming part hereof.

In general terms the method of making cast structures hereof includes improvements in the method set forth in my said prior application, Serial No. 586,721, and is particularly adapted for making relatively high or deep dome shells, and includes the use of one or more domeshaped inner molds, and independently supported preferably separable members forming an outer mold which is movable into and out of position with respect to the inner mold or molds so as to form a mold cavity or cavities in which the structure is cast with its material in engagement with the outer mold, and after the material of the cast strucure has attained an initial set, the outer molds and the cast structure engaged thereby are separated from the inner mold or molds, and the outer mold is disengaged and separated therefrom for permitting the material of the cast structure to attain a final set, whereby after removal of the cast structure with its material in the condition of initial set from the molds, adequate shrinkage of the material of the cast structure is attainable during the further setting process, whereby substantially any desired mix may be employed without the otherwise usual losses which occur when dome shells are cast and permitted to attain a permanent set before removing the inner molds.

The casting apparatus of the present invention includes in general the improvements in casting apparatus set forth in my said prior application, Serial No. 586,721, and more particularly includes longitudinally spaced jack members or frames, means for simultaneously moving the jack members or frames selectively in either one of opposite directions, one or more inner molds located between the jack members or frames, preferably separable members forming an outer mold, each of the separable members being preferably adjustably supported either on one of the jack members or frames, or with one end on one and one end on the other, the outer mold being thus arranged for being supported solely by the jack members or frames, and the outer mold being preferably arranged for engagement with a structure cast in the mold cavity formed when the outer and inner molds are in mold cavity forming position, whereby movement of the outer mold away from the inner mold serves to strip the cast structure from the inner mold or molds, and the foregoing being preferably provided with other improved details of construction, as are hereinafter more fully set forth.

Preferred embodiments of the improved apparatus hereof, preferably adapted for carrying out the improved methods, are illustrated in the accompanying drawings forming part hereof, in which I Figure 1 is a fragmentary side elevation of an embodiment of the improved apparatus, as arranged for making half-sections of concrete septic tanks, with portions broken away and illustrated in section;

Fig. 2, a fragmentary end elevation thereof, with portions broken away and illustrated in section;

Fig. 3, an enlarged plan sectional View thereof, as on line 3 3, Figs. 1 and 2, with portions broken away andillustrated in section, and the inner and outer molds being associated with suitable cores for making the top half-section of a concrete septic tank, and the inner and outer molds being in their relative positions for having the top half-section of a septic tank cast therein;

Fig. 4, a longitudinal vertical sectional view thereof as on line 4 4, Fig. 3, and with the top half-section of a concrete septic tank cast between the molds;

Fig. 5, a similar view illustrating the arrangement of cores for making the bottom half-section of a concrete septic tank, and with the bottom half-section of a concrete septic tank cast between the molds;

` Fig. 6, an end elevation and transverse sectional view of the apparatus as on line 6 6, Fig. 1, illustrating the relative arrangements of the parts just after the half-section of a concrete septic tank has been cast;

Fig. 7, a view similar to Fig. 6, illustrating the outer mold with the cast tank half-section separated from the inner molds by operation of the apparatus to elevate the outer mold and cast tank half-section;

Fig. 8, a similar view illustrating the' outer mold bodily separated from the cast tank halfsection, the cast tank half-section resting on the preferred separable lifting and engaging ring member, and the ring member being preferably provided with wheels for rolling on a length of track placed 'beneath the wheels as illustrated, whereby the ring member and the tank half-section carried thereon may be laterally rolled away from the remaining parts of the casting apparatus, in carrying out the improved methods;

Fig. 9, an enlarged fragmentary transverse sectional View of the apparatus, similar to Fig. 6;

Fig. 10, a similar fragmentary transverse sectional View thereof as on line 10 l0, Fig. 1; Fig. 11, a detached isometric View illustrating one of the preferred separable combined engaging and socket forming members, preferably for the outer mold members of the apparatus;

Fig. 12, a detached fragmentary oblique View illustrating the improved apparatus with an inner mold adapted for making grave vaults; and

Fig. 13, a longitudinal vertical sectional View illustrating cast top and bottom half-sections of an improved septic tank, made by the improved methods and apparatus, and assembled together as a complete tank.

Similar numerals refer to similar parts throughout the drawings.

The improved casting apparatus is indicated generally by 10 and for most advantageously carrying out the improved methods, the lower portions of the casting apparatus 10 are preferably located in a pit 11 which extends laterally, preferably between opposite spaced ends of track sections 12--1 and 12--2 Which are laid upon the ground or` floor surface 13.

For facilitating the carrying out of the improved methods as will hereinafter be set forth in greater detail a portable track section 12-3 is provided for selectively bridging across the top of the pit 11 and connecting the opposite ends of the sections 12-1 and 12-2.

The casting apparatus includes a base 14 which rests upon the bottom 15 of the pit l1. Laterally spaced corner posts 16a-1 and 16a- 2 are secured at their lower ends to one end 17a of the base 14 and extend upwardly thereifrom; and similarly, laterally spaced corner posts 1Gb-1 and 16b--2 are secured at their lower ends to the other end 1717 of the base and extend upwardly therefrom.

The upper ends of the posts 16a- 1 and 16a-2 are secured to and support a gear mounting and bearing bracket 18a; and similarly, the upper ends of the posts 16h-1 and 16h- 2 are secured to and support a gear mounting and bearing bracket 18b.

Members forming improved inner and outer molds indicated generally by 29 and 32, respectively, are located above the base 14 and etween the posts 16a-1 and 16a- 2, and the posts 1612-1 and 1Gb-2, and the height of these posts is such that the distance between the base 14 and the brackets 18a and 18h is preferably over three times the overall height of the mold forming members, for enabling the preferred operation of the apparatus for carrying out the improved method, as will be hereinafter set forth in greater detail.

A jack screw shaft 20a is preferably located between the posts 16a-1 and 16a-2, and the shaft 20a is journalled at its lower end in the end 17a of the base 14, and the shaft 20a is journalled adjacent its upper end in the bracket 18a, and the shaft 20a preferably extends above the bracket 18a, and a bevel gear 21a is secured upon the upper end of the shaft 20a, above one side of the bracket 18a.

Similarly, a jack screw shaft 20h is preferabiy located between the posts 16h- 1 and 1Gb- 2 and the shaft 2Gb is journalled at its lower end in the end 1719 of the base 14, and the shaft 20a is journalled adjacent its upper end in the 1bracket 18h, and the shaft 20a preferably extends above the bracket 18D, and a bevel gear 2lb is secured upon the upper end of the shaft 2Gb above one side of the bracket 18h.

The bracket 18a includes an angled arm 22a extending laterally from one side of the bracket and upwardly at one side of the bevel gear 21a; and similarly the bracket 18D includes an angled arm 22h extending laterally from one side of the bracket and upwardly at one side of the bevel gear 2lb.

The arms 22a and 22h are preferably arranged as illustrated, so that the arm 22a, is located between the set of posts 16a- 1 and 16d-2, and the set of posts 16h-1 and 16b--2, and the arm 22D is located on the other or outer side of the set of posts 16h- 1 and 16h-2.

The arm 22a preferably terminates in a bearing block 23a which is preferably located above the bevel gear 21a; and similarly the arm 22h terminates in a bearing block 23h which is preferably located above the bevel gear 2lb, and the bearing blocks 23a and 23h have journalled therein a drive shaft 24 which extends longitudinally between and through the bearing blocks, as illustrated.

A bevel pinion 25a is secured on the end of the shaft 24'adjacent the bevel gear 21a, and the pinion 25a is meshed with the gear 21d.

A bevel pinion 25h is secured on the shaft 24 between the bearing blocks 23a and 23h, and the pinion 25?) is meshed with the gear 2lb.

A chain drive wheel 26 is secured upon the end of the shaft 24 on the outer side of the bearing block 23h, and an endless pull chain 27 may be meshed with a suitably socketed peripheral groove. 28 which as illustrated is provided for the chain drive wheel 26.

The chain 27 is preferably of sufficient length so that when applied to the wheel 26, the chain 27 will hang down substantially to the ground level 13, in order that the chain may be easily grasped by the operator of the apparatus; whereby a pull on the chain will cause rotation of the Wheel 26 and of the shafts 20a and 20h, by reason of the above described gearing and drive shaft connection between the shafts 20a and 20h and the wheel 26.

Obviously the direction of rotation of the shafts 20a and 20h depends upon which side portion of the chain 27 is grasped and pulled by the operator.

Normal rotation of the drive shaft 24 is preferably eifected by means of a motor 60 which is mounted on a base channel 61 extending between and being supported on the brackets 18a and The motor 60 is operatively connected with the shaft 24 as by means of a pinion 62 secured on one end of the motor shaft 63, and meshed with a gear 64 which is secured on the drive shaft 24.

The motor 60 is a reversing motor, and is supplied with power from any usual power line, not shown, and is controlled by any usual reversing switches and suitable auxiliary controlling apparatus, not shown.

The bevel pinions 25a and 25h are the same size and have the same number of teeth, and the bevel gears 21ar and 2lb are the same size and have the same number of teeth, and accordingly the jack screw shafts 26a and 20h rotate at the same speed.

The threads of the jack screw shafts 2a and 2Gb have the same pitch, and the shaft 23a, is screw connected with a jack frame 70a which is slidably mounted on and thus guided by the posts 16a1 and 16a-2.

Similarly, the jack screw shaft 20h is screw connected with a jack frame 10b which is slidably mounted on and thus guided by the posts 16b-1 and 1Gb- 2.

Accordingly the jack frames 70e and TG1, will be raised or lowered simultaneously, and at the same speed, depending upon the direction of rotation of the jack screw shafts 20a and. 29h. 1n other words the improved apparatus 10 includes the longitudinally spaced jack frames 'lila and 70h, and means for simultaneously raising and lowering the jack frames preferably at the same speed.

As illustrated, the jack frame 70a preferably includes a laterally and transversely extending web member 71a, and transversely spaced laterally extending upper and lower ribs 43a which protrude outwardly from the outer face of the web member 71a; and the ribs 48a have formed therein guide bearing apertures '72a-1 and 720,-2 which slidably fit respectively on the posts 16-1 andl6a-12 and the upper rib 48a, of the jack frame 70a has formed therein an aperture 72a--3 through which the screw shaft 20a slidably extends; and the lower rib 48a of the jacl; frame 70a, has secured therein a nut 49d, and the shaft 20a extends through and screws in the nut e220..

Similarly as illustrated, the jack frame 70h preferably includes a laterally and transversely extending web member 71h, and transversely spaced laterally extending upper and lower ribs @8b which protrude outwardly from the outer face of the web member 711); and the ribs e819 have formed therein guide bearing apertures 72bl and 72b-2 which slidably fit respectively on the posts 16h-l and 1Gb-2; and the upper rib 4819 of the jack frame 7Gb has formed therein an aperture 72b-3 through which the screw shaft 20h slidably extends; and the lower rib 48o of the jack frame 70h has secured therein a nut 49h, and the shaft 20o extends through and screws in the nut 49D.

As is hereinafter set forth in greater detail, the jack frames 70a and 7019 provide the sole supporting or suspending means for the outer mold 32, whereby the outer mold 32 may be raised, lowered, or maintained at any desired elevation, during operation of the apparatus.

Also, as is hereinafter set forth in greater detail, the inner molds 29 are normally releasably secured upon the base 14, but when it is desired to change the inner molds, in order to change the product to be cast, the inner molds are released from the base lll, and the inner and outer molds are arranged so that the inner molds 29 may be selectively supported on the outer mold 32, whereby when the inner molds are supported by the outer mold 32, raising and lowering of the outer mold 32 serves to raise and lower the inner molds 29.

The improved molds 29 and 32 as illustrated, are arranged for making half-sections of septic tanks. The inner molds 29 include a plurality of dome-shaped molds 29-1, 2.9-2, 29-3, and 29-4.

The inner mold 2.9-1 includes longitudinally spaced laterally extending end walls 29-1a and 2li-db, the side corners of which are connected by and merge with the end corners of longitudinally extending laterally spaced side walls 29-1c and 29--1d, and the upper corners of the side and end walls are connected by and merge with the outer corners of a top wall 25J-le.

From the lower corners of the end and side walls, there extends inwardly a peripheral flange 29-12, by which the dome-shaped inner shell member 29-1 is separably secured toy the base 14 as by means of bolts 30 and nuts 31, the shanlrs of the bolts extending through suitable egistering apertures in the flange 29-1f and the rase le, and the nuts 3l being screwed on the threaded ends of the bolts and serving to clamp the flange 29-11 and the base 14 between the nuts and the heads of the bolts in a usual manner.

Each of the inner molds 29-2, 29-3, and 29-4 is generally similar to the inner mold 29-1 in its construction and in its mode of being separably secured to the base lll.

The molds 29-1 and 29-4 comprise end molds, and the molds 29-2 and 29-3 comprise intermediate molds, which are longitudinally spaced from each other and from the end molds for purposes hereinafter to be set forth in greater detail.

Similar sets of side walls of all the inner molds are alined with each other as illustrated.

The outer mold indicated generally by 32 is preferably formed of separable members, and is adapted for being moved into and out of position with respect to the inner molds 29-1, 29-2, 29-3, and 29-4, so that when the molds are in mold cavity forming position, a mold cavity indicated generally by C is formed between the outer and inner molds.

As illustrated, the outer mold 32 includes a laterally extending end wall member 32a whose inner face is longitudinally spaced from the outer face of the outer end wall of the inner mold 29-1 when the molds are in mold cavity forming position.

Similarly, the outer mold 32 also includes a laterally extending end wall member 32D Whose inner face is longitudinally spaced from the inner face of the outer end wall of the inner mold 2Q-l when the molds are in mold cavity forming position.

The outer mold 32 furthermore includes a longitudinally extending side wall member 32c whose inner face is laterally spaced from the alined outer faces of one set of side walls of the inner molds 29-1, 29-2, 29-3, and 29-4, when the molds are in mold cavity forming position.

Similarly, thev outer mold 32 includes a longitudinally extending side wall member 32d whose inner face is laterally spaced from the alined outer faces of the other set of side walls of the inner molds when the molds are in mold cavity forming position.

For permitting movement of each of the members of the outer mold 32 away from the outer surface of the product cast in the mold cavity C, after the product has set, and thereby facilitating stripping of the outer mold from the cast product, the outer mold end wall member 32a is adjustably mounted on the jack frame "100., and the outer mold end wall member 32D adjustably mounted on the jack frame 7017, and the outer mold side wall member 32o extends between and is adjustably mounted on one set of similar sides of the jack frames '70a and 7Gb, the outer mold side wall member 32d vextends between and is adjustably mounted on the other set of similar sides of the jack frames '70d and 7Gb.

For the purpose of adjustably mounting, as aforesaid, the outer mold end wall member 32a on the jack frame 70a., as illustrated, the jack frame '76a includes laterally spaced side members 'i3d-l and i3d-2 extending longitudinally from the web member '71a towards the jack frame "Mib, and the side members 'ZZBcL-l and 'Bor-2 each has formed therein a plurality of transversely spaced longitudinally extending slots 74. The outer mold end wall member 32a has formed at one side a flange 32a-1 and at the other side a iiange 32a-2, and the flanges 32a-1 and 32a-2 extend towards the web member 71a between the side members 73a--1 and 73a-2, and the outer faces of the flanges 32a- 1 and 32a--2 slidably abut respectively against the inner faces of the side members 7Bn-1 and 7311-2, and the anges 32al and 32a-2 have apertures '75 formed therein which register with the slots '74 of the side members 'i3d-1 and 7311-2.

Bolts 'l5 and nuts 77 are provided, as illustrated, for connecting the flanges 32a-4 and 32a 2 of the end wall member 32a, respectively, with the side members i3d-l and 'i3d-2 of the jack frame 70a., and the shank of one of the bolts 76l extends through each registering flange aperture and side member slot 74, and preferably the heads of the bolts 76 abut against the inner faces of the end wall member flanges, and the threaded ends of the bolts extend beyond the outer faces of the slotted side members, and one of `the nuts 7'1 is screwed on each threaded outer end of each bolt 76, thereby permitting clamping of the end wall memberv 32a, in the normal position for casting as best illustrated in Fig. 3, with the Shanks of the bolts 76 located in the ends of the slots 74 farthest removed from ther web member 71a.

When it is desired to displace the outer mold end wall member 32a away from the inner molds 29 and towards the web member 71a, it is only necessary to loosen the nuts 77, and to pry the end wall member 32a in the desired direction.

For the purpose of facilitating the desired displacement of the end wall member 32a by prying with a crow bar or the like, the side members 73a-1 and 73a-2 of the jack frame 70a are provided with apertures 78 each of which is horizontally alined with, but longitudinally olfset from an aperture 79 formed in the adjacent flangev 32a-1 or 32a-2 of the side wall member 32a.

Accordingly, when the end wall member 32a is in the normal position for casting illustrated in Fig. 3, and after the nuts 77 have been loosened, the end of a crow bar may be inserted into each set of offset 'apertures 78 and 79, whereby the end wall member 32a may be pried away from the inner molds 29.

As illustrated, the end wall member 3212 is adjustably mounted in the jack frame 7012 in a manner similar to the preferred adjustable mounting just described of the end wall member 32a. on the jack frame 70a, the jack frame 7012 being provided with side members 7312-1 and 7312-2, and the side members. 7312-1 and 7312-2 being provided with slots 74, and the end wall member 3212 being provided with flanges 3212-1 and 3212-2, and the flanges 3212-1 and 3212-2 being provided with apertures 75 registering with the slots 74 of the side members 7312-1 and and 73 12-2, and bolts 76 and nuts 77 adjustably connecting the flanges 3212-1 and 3212-2 of the end wall member 3212, respectively, with the side members 7312-1 and 7312-2 of the jack frame 7012.

The side members 7312-1 and 7312-2 are likewise providedwith prying apertures 78 cooperating with prying apertures 79 provided in the flanges 3212-1 and 3212-2.

For the purpose of adjustably mounting, as aforesaid, the outer mold side wall member 32d on one set of similar sides of the jack frames 70a and 7012, as illustrated, the side member 73a-1 of the jack frame 70a is provided with a transversely land laterally extending flange 7912-1 which protrudes outwardly from the side member 7311-1, and which has formed therein a plurality of apertures 80. IThe adjacent end of the outer mold side wall member 32d is provided with a transversely and laterally extending end flange Sla-1, which protrudes outwardly from the side wall member 32d, and which abuts against the flange 79a-1 of the side member 73a-1.

The side member 7312-1 of the jack frame 7012 alined with the side member 73w-1 of the jack frame 70a is similarly provided with a flange 78512-1 having yapertures 80 formed therein, and the end -of the .outer mold side wall member 32d adjacent `the flange 7912-1 is similarly provided with an end flange 8112-1 abutting against the flange 7912-1, and the flange 8112-1 is similarly provided with a plurality of laterally extending slots 82 which register with the apertures 80 in the flange 7912-1.

Bolts 83 and nuts 84 are provided, as illustrated, for connecting the end flanges 8111-1 and8112-1, respectively, with the flanges 79a-1- and 7912-1, in a. manner similar to the connectiens heretofore described by which the bolts 76 and nuts 77 adjustably connect the end wall member vflanges with the jack frame side members.

When it is desired to displace the outer mold side wall member 32d away from the inner molds 29, it'is only necessary toloosen the nuts 84, and to pry the side wall member 32d in the desired direction.

For the purpose of 'facilitating the desired displacement of the sidewall member 32d by prying with a crow barror the like, the side wall member flanges 79a-1 and 7912-1 are provided with notches 85, and a tongue ange 86a-1 is provided on the flange Sla-1 and overlaps the notches 85 of the flange 7912-1, and the flange 8112-1 is provided with a tongue flange 8612-1 overlapping the notches 85 of the Accordingly, when the side wall member 32d is in the normal position for casting illustrated in Fig. 3, and after the nuts 84 have been loosened, the end of a crow bar may be inserted in each notch 85, and pried against the overlapping flange 86a-1 or 8612-1, whereby the Outer mold side wall member 32d will be displaced away. from the inner molds 29.

As illustrated, the outer mold side wall member 32o is adjustably mounted on the other set of similar side members 73612-2 and 7312-2 vof the jack frames 70a and 70,12, in a manner similar to the preferred adjustable mounting just describedof the side wall member 32d on the side members 73a-1 and 7312-1, the jack frame 70a being provided with a flange 7912-2 protruding outwardly' from the side members 73a-2, and the jack frame 7012 being provided with a flange 7912-2 protruding outwardly from the side member 7312-2, and a plurality of apertures being provided in each of the flanges 79a-2 and 7912-2, and the side wall member 32e being provided with endilanges 8111-2 and 8112-2, and the end flanges Sla-2 and 8112-2 being provided with a plurality of laterally extending slotsl 82 which register with the apertures 80 in the anges '19a- 2 and 7912-2, and bolts 83 and nuts 841 adjustably connecting the flanges Sla-2 and 8112-2, respectively, with the flanges 79a-2 and 7912-2.

The flanges 79a-2 and 7912-2 are likewise provided with notches 85, and the ilanges 8111-2 and 8112-2 are likewise provided respectively with overlapping tongue flanges 8600-2 and 8612-2.

The youter mold members furthermore include an engaging and lifting ring ledge member indicated generally by 3 6 which includes longitudinally -spaced laterally extending end sections 36a and ,3 612 connected at their `extremities with the extremities of laterally spaced longitudinally extending yside sections 36o and 36d.

The ring ledge member 36 may be channelshaped as illustrated, and is preferably removably seoured .to the Vouter mold so that the upper preferably flat ledge face 37 of the ring ledge member 36 abuts against the lower ends of the members of the outer mold 32 and extends therefrom towards the inner molds 29-1, 29-2, 29-3, and 29-4, preferably so that the inner sides of the ledge member sections 36a,'36b, 36o, and 36d may slidably abut against and be centered by the opposite outer faces of the inner member walls 29-1, 29-2, 29-3, and 29-4.

Transversely spaced longitudinally extending ribs 38, and longitudinally spaced transversely extending ribs 39 preferably protrude from the outer face of each of the outer mold side members 32e and 32d, and the ring ledge member 36 has formed therein a plurality of apertures 49 each of which may be registered with one of a plurality of apertures 41 formed in the opposite lowermost ribs 38 of the side members, whereby the ring ledge member may be separably secured in abutment against the lower ends of the members of the outer mold 32, as by means of bolts 42 and nuts 43, the shank of each bolt extending through one of the sets of registering apertures and 41, and the head of each bolt as illustrated abutting against the underside of the web of the channel-shaped ring ledge member, and one of the nuts 43 being screwed on the threaded end of each bolt against the opposed rib 38.

Oppositely iianged wheels 44o are longitudinally spaced with reference to the ring ledge member section 36e, and each wheel 44e is journalled in a bracket 45e which is secured to the outer side of the ring ledge member section 36o.

Similarly, opposi'tely flanged wheels 44d are longitudinally spaced with reference to the ring ledge member section 36d, and each wheel Lljld is journalled in a bracket 45d which is secured to the outer side of the ring ledge member section 36d.

The spacing of the wheels is of the proper gauge so that the wheels and ring member 36 constitute a car which may roll on the track sections 12-1, 12-2, and 12-3, for purposes hereinafter to be set forth in greater detail.

A relatively narrow lower longitudinally extending portion 46c of the side Wall member 32o is laterally and outwardly offset with respect to the remaining upper longitudinally extending portion 47C.

Similarly, a relatively narrow lower longitudinally extending portion 46d of the side wall member 32d is laterally and outwardly offset with respect to the remaining upper longitudinally extending portion 47d.

Accordingly, the spacing of the inner faces of the lower portions 46c and 46d from the opposite portions respectively of the outer faces of the side Walls of the inner molds is greater than the spacing of the inner faces of the upper portions 47e and 47d respectively from the outer faces of the side walls of the inner molds.

Longitudinally spaced combined socket forming and engaging members 50 may be separably secured upon the inner face of the lower portion l6c of the side wall member 32e and likewise upon the inner face of the lower portion 46d of the side wall member 32d, as by means of cap screws 5l, the shanks of which extend through apertures provided in the side members 32o and 32d and the threaded ends of which screw into threaded apertures 52 provided in the socket forming and engaging members 59.

For facilitating stripping of the cast product from the inner molds, the top wall of each inner mold is preferably provided with a plurality of air valve openings 90, in the upper end of each of which a valve disk 91 is seated, and means such as a spring yoke 92 is secured to the lower face of each valve disk 91 for limiting the displacement of each valve disk from its seat.

As illustrated, the end inner mold 29-1 has a notch pocket 29--1a formed in its outer end wall 29-1w, and the notch pocket 2.9-1a' is adapted for having located therein either a tank inlet or outlet core assembly 93, or a filler core 94 depending upon whether the upper or lower half-section of a septic tank is to be cast.

The outer end wall 29-4 of the end inner mold 29-4 is similarly provided With a notch pocket 29-4, which is likewise adapted for having located therein either a core assembly 93 or a ller core 94.

Filler cores 95-1 and 95-2 are also preferably provided for being releasably located between opposite end faces of the inner molds, in order to form partition walls of the desired heights in the cast septic tank half-sections.

Bridge members 96 are also preferably provided for being releasably located between the lower opposite end faces of the inner molds, with the ends of the bridge members 96 supported on the side sections of the ring member 36, and the upper faces of the bridge members 96 are preferably ridged for forming V grooves in the outer end faces of the partition walls of the tank half -sections cast between the molds.

For similar purposes, ridge cores 97 are laid upon the upper faces of the ring member 36 between the outer mold 32 and the inner molds 29.

In order to permit easy changing of the inner molds, each inner mold is preferably provided in each of its side walls with a plurality of aper-` tures 98, each of which registers with a set of registering apertures 99 preferably provided in the legs of the channel-shaped ring ledge member 36, whereby when the bolts and nuts 30 and 31 are removed, bolt Shanks may be inserted through each set of registering apertures 98 and 99, and the inner molds may be elevated from the base 14 for facilitating removal of the same therefrom, and substituting other inner molds for making other products.

For facilitating removal of the bolts 30 and nuts 31, a sub-pit 190 is formed beneath portions of the base lll, and a laterally extending passage 191 permits entrance to the sub-pit 100 from the bottom 15 of the pit l1.

In Fig. 9 is illustrated a novel cast concrete septic tank indicated generally by 110 and made by the use of the improved methods and apparatus, and which includes a top half-section 111, and a bottom half-section 111. The top halfsection 111 includes a relatively high dome shell having laterally extending longitudinally spaced end walls llla, and lllb, the sides of which are connected by and merge with the ends of lon-- gitudinally extending laterally spaced side walls 1l1c and llld, and the upper ends of the side and end walls are connected by and merge with the outer portions of a top wall 111e. All the walls are preferably formed of reinforced concrete, and the end wall 111al and adjacent portions of the top wall 111e also preferably include an inlet or outlet duct lllf, and similarly the end Wall lllb and adjacent portions of the top Wall 111e preferably include another inlet or outlet duct 111f.

Longitudinally spaced partition walls 111g, lllh, and 1117s extend'- -laterally between the side walls lllc and llld, and the lower faces of the half-section end walls, side walls and partition walls, are all in the same plane, and preferably each have formed therein a V groove 113. Longitudinally spaced hand or hook sockets 114 are preferably formed in the outer face of each of the side walls lllc and llld.

rihe upper faces of the partition walls 111g and 111k' terminate in the same plane spaced below the inner face of the top wall 111e, and the upper face of the partition wall lllh is spaced below the plane of the upper faces of the partition walls 111g and 1117s.

The bottom half-section 111 of the tank is generally similar to the top half-section 111, and in use is inverted so that the grooved faces of the end, side and partition walls are uppermost, and register with the grooved faces of the top half-section lll, with grout or similar material indicated by 115 sealing the joint between the grooved faces.

The center partition lllh of the bottom half-section extends from the grooved faces to the upper face of the wall llle of the bottom half-section, and the bottom half-section does not include any inlet or outlet ducts.

In using the improved apparatus 10, to carry out the improved methods, the inner mold or molds are arranged for the particular product to be cast, as for example in Figs. 3 and 4 the inner molds 29 are arranged with suitable cores for casting the top half-section lll of the novel concrete septic tank 110, and in Fig. 5 the inner molds29 are arranged with suitable cores for casting the bottom half-section 111', and in each case the outer mold 32 and the lifting and engaging ring member 36 supported from the bottom thereof, as aforesaid, have been lowered about the inner molds.

The socket forming members 50 in each case are preferably provided on the outer molds, as aforesaid, and after the molds have been positioned as illustrated in Fig. 4 or 5, reinforcing R is applied about the inner molds and between the inner and outer molds, and concrete is poured between the molds, and applied over the top walls of the inner molds, and the desired dome shell structure is cast, as for example the tank top half-section 111 in Fig. 4, or the tank bottom half-section 111' in Fig. 5.

The pit 1l and the sub-pit 100 is each preferably of ample size to permit the operator or operators of the apparatus to walk around the same during operation of the apparatus.

The material of the dome shell structure thus cast in each case has its lower ends in engagement with the upper ledge face 37 of the ring member 36 and also the socket forming members 50 are in engagement with the side walls of the cast structure.

After the initial set has been attained in the cast structure, the drive shaft 24 is rotated in the proper direction either by the motor 60 or the chain 27, so as to rotate the shafts 20a and 2Gb in the direction to separate the outer mold 32 and the cast structure engaged thereby from the inner molds 29, by elevating the outer mold 32 and the cast structure engaged thereby from the casting position, illustrated in Figs. 1, 2, 3, 4, 5, and 6, to the intermediate position, illustrated in Fig. 7.

The initial set may be attained for example in substantially 6 hours, after the expiration of which as aforesaid the parts of the apparatus are separated to the positions illustrated in Fig. 7.

Stripping of the cast structure from the inner molds is facilitated by the air valve openings 90 each provided as aforesaid with a valve disk 9i, the operation of which to admit air beneath the inner faces of the top of the cast structure prevents formation of a vacuum between the cast structure and the inner molds.

After the parts have 'been positioned as illustrated in Fig. 7, the nuts 43 are unscrewed from the bolts 42, and the bolts 42 are removed from the registering apertures 40 and 41, whereby the lifting ring member 36 is disengaged from the side and end wall members of the outer mold 32.

The cap screws 51 are also unscrewed and removed, whereby the socket forming members 5o are disengaged from the side members 32e and 32d of the outer mold 32.

Also, the side members and end members of the outer mold 32 are preferably displaced away from the inner molds and the cast structure, as heretofore described.

Also, the track section 12--3 is bridged across the top of the pit 11 so that the wheels 44o and 44d of the ring member 36 rest upon the rails of the track section 12-3.

The drive shaft 24 is then rotated so as to further elevate the displaced side end members of the outer mold 32 to the position illustrated in Fig. 8, wherein the side and end members are separated from the ring member 36, and the ring member 36 with its green cast structure in supporting engagement thereon may be rolled on the track laterally away from the apparatus, so that the cast structure may attain a final set away from the apparatus.

Another ring member 36 is then connected to the outer mold side and end members, together with another set of handle members 50, and another structure may be immediately poured after the apparatus parts have been moved to their casting position, as illustrated in Figs. 1 to 6 inclusive.

Each structure thus cast and removed from the apparatus with its material in the condition of initial set is each rolled on its own ring member 36 to any desired location for seasoning and final hardening.

The inner molds may be changed to make different structures as heretofore described, and in Fig. 12 is illustrated the improved apparatus as set up for making grave vaults, with one cast grave vault shown at one side of the apparatus.

The apparatus as set up in Fig. 12 is similar to the apparatus as set up in my said prior application, Serial No. 586,721, with the exception that the apparatus of Fig. 12 is provided with the improvements hereof.

I claim:

The method of making massive hollow cast structures of plastic material by the use of inner and outer mold members, which includes casting the structure of plastic material between the inner and outer mold members, elevating the cast structure together with the outer mold members to be entirely above the inner mold member after the plastic material has attained an initial set, and then elevating the outer mold members as a unit to be entirely above the cast structure.

HARRY J. HICK. 

